Green, green, green ... is the hydrogen that has powered the Linde Material Handling (MH) plant fleet since May 11, 2023. The energy for the 21 fuel cell trucks is produced with the help of an infrastructure that is unique in Europe. The aim of the pilot project is to gather empirical values and build up expert knowledge in order to be able to provide customers with comprehensive advice and support on the use of hydrogen in material flow processes. The investment is funded by the German Federal Ministry of Digital Affairs and Transport (BMDV). The coordination and implementation was carried out in each case by NOW GmbH and by Projektjäger Jülich (PtJ).
This also applies to applications in intralogistics. In addition to the potential climate neutrality, the rapid refueling of the industrial trucks with hydrogen is a particular advantage in intensive multi-shift operations. A three-minute refueling time, for example, corresponds to a comparable charging power of approx. 480 kW. Another plus point is that the energy carrier can act as an energy store in the event of greater use of regenerative energy sources in the future, for example to temporarily store electricity generated by photovoltaics or wind power.
Full speed ahead into a green future
The planning and construction of the new hydrogen infrastructure took around 2.8 million euros. The production facility was built on an existing 280 square meter site at a convenient location within the production and assembly plant.
Within the eleven-month construction period, around 50 subcontractors were involved in the construction of the hydrogen infrastructure under the direction of the general contractor Covalion, a Framatome brand, and the construction department of Linde MH.
Modern technology in inconspicuous containers
The plant components of the hydrogen infrastructure are divided into several modules. The heart is a PEM (polymer electrolyte membrane) electrolyzer, which is set to produce 50 kg of hydrogen per day. Here, purified and deionized drinking water is separated into oxygen and hydrogen with the help of green electricity.
In another container, the hydrogen is gradually compressed to 450 bar and then fed into the high-pressure storage tanks via pipelines and valves. A software-controlled valve system regulates the supply line to the dispenser. With just a few simple steps, the vehicles can be connected there and refueled within a short time. The high-pressure storage tank is designed to store up to 120 kg of hydrogen at 450 bar. This covers possible peak demand caused by increased refueling at shift change.
The introduction of the new infrastructure has also brought some changes to the plant fleet. For example, nine Linde E35 and twelve Linde E50 electric counterbalance trucks with fuel cell hybrid systems are replacing models with combustion engines that were previously in use. The vehicles, with load capacities of 3.5 and 5 tons, are used, among other things, to load and unload trucks and supply assembly lines with large and heavy components, such as counterweights, pre-assembled ramen or driver cabs.
In the process, the new trucks enable operation without emissions: In the vehicle's fuel cell system, a reaction takes place between the hydrogen and the oxygen in the ambient air. This produces electrical energy that charges a lithium-ion battery, which in turn powers the truck. The only byproducts are water and heat. Another ecological advantage? The hydrogen is produced directly where it is used.
In addition to the Linde forklifts, the explosion-proof access control of the Linde:connect fleet management solution is also used. This ensures that only authorized and trained persons can use the hydrogen system. The explosion-protected safety assistance solution "Safety Guard" at the dispenser and in the vehicles also automatically reduces the speed of the trucks in the vicinity of the filling station, thus increasing safety. Finally, the "Linde Energy Manager" energy management solution enables intelligent planning and control of energy requirements throughout the site, avoids power load peaks and serves to optimize costs.
Hydrogen pioneer Linde MH
In the intralogistics sector, Linde MH has so far played a pioneering role in the use of hydrogen. In 2000, the company presented the first fully operational prototype forklift with fuel cell drive. Ten years later, the starting signal was given for series production. Today, 80 percent of the series, including counterbalanced trucks, tractors and high-lift trucks, are available as "customer-specific solutions" with H2 drive.
To further promote acceptance of the technology, numerous studies and projects have already been published by Linde MH with partners from industry and science. These show under which conditions fuel cell forklifts are marketable and already economical today. This is the case, for example, if a hydrogen infrastructure is already available on site or if highly pure hydrogen is produced as a waste product in the operational process. The advantages of fuel cell forklifts come to the fore, on the one hand, in multi-shift operation with intensive use and high annual operating hours indoors. But the vehicles can also show their strengths when there is limited space for charging or battery changing equipment, which also needs to be saved.
The construction of the hydrogen infrastructure in Aschaffenburg is just one milestone in Linde MH's hydrogen strategy. The parent company, KION GROUP AG, is also currently pushing ahead with the development and production of its own fuel cell systems. At the last LogiMAT, Linde MH presented its first 24-volt system for warehouse equipment, which was also developed at the Aschaffenburg site. The team is currently working hard on the development of a 48-volt fuel cell system, which has also been approved for funding.